Homes correctly, but Z axis messes up when printing

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User avatar
mlapaglia
Printmaster!
Posts: 121
Joined: Sat May 24, 2014 10:41 am
Location: Indianapolis, IN

Homes correctly, but Z axis messes up when printing

Post by mlapaglia »

smoothieboard 4x configured for a delta printer
Here's a quick pic: mattlapaglia dot com /wp-content/uploads/2015/02/IMG_20150208_223541 (dot) jpg

The three towers home correctly towards the max end stops. Moving the effector around manually works as expected. When I try to print an object the gamma axis always jams upwards while the other two axis perform normally.

I've switched the end stops and motors around to make sure it wasn't anything with those particular components.

Here is some gcode from Cura, set with the "hardware center at 0, 0" checked in the config:

[

Code: Select all

]
M190 S70.000000
M109 S230.000000
;Sliced at: Thu 18-06-2015 15:31:36
;Basic settings: Layer height: 0.2 Walls: 1 Fill: 10
;Print time: 2 hours 30 minutes
;Filament used: 3.527m 27.0g
;Filament cost: None
;M190 S70 ;Uncomment to add your own bed temperature line
;M109 S230 ;Uncomment to add your own temperature line
G21        ;metric values
G90        ;absolute positioning
M107       ;start with the fan off
G28   ;move to endstops
G92 E0                  ;zero the extruded length
G1 F200 E3              ;extrude 3mm of feed stock
G92 E0                  ;zero the extruded length again
G1 F9000
;Put printing message on LCD screen
M117 Printing...

;Layer count: 201
;LAYER:0
M107
G0 F9000 X22.208 Y-17.235 Z0.300
;TYPE:SKIRT
G1 F1200 X22.719 Y-16.569 E0.01974
[
]

If I execute the G0 command manually, it performs as expected. When I execute the actual gcode file though, the gamma axis pushes up into the end stop, forcing me to shut off the machine.

I upgraded to the latest stable firmware and started from a fresh config file for the delta style printers.

Any help would be appreciated!

User avatar
KAS
ULTIMATE 3D JEDI
Posts: 1157
Joined: Thu Dec 04, 2014 6:06 pm

Re: Homes correctly, but Z axis messes up when printing

Post by KAS »

Can you post your config file? Also have you checked M119, is showing the correct tower end stop is working when manually holding the switch?

User avatar
mlapaglia
Printmaster!
Posts: 121
Joined: Sat May 24, 2014 10:41 am
Location: Indianapolis, IN

Re: Homes correctly, but Z axis messes up when printing

Post by mlapaglia »

Code: Select all

# NOTE Lines must not exceed 132 characters
# Robot module configurations : general handling of movement G-codes and slicing into moves
default_feed_rate                            4000             # Default rate ( mm/minute ) for G1/G2/G3 moves
default_seek_rate                            4000             # Default rate ( mm/minute ) for G0 moves
mm_per_arc_segment                           0.5              # Arcs are cut into segments ( lines ), this is the length for
                                                              # these segments.  Smaller values mean more resolution,
                                                              # higher values mean faster computation
#mm_per_line_segment                         0.5              # Lines can be cut into segments ( not useful with cartesian
                                                              # coordinates robots ).
delta_segments_per_second                    100              # for deltas only same as in Marlin/Delta, set to 0 to disable
                                                              # and use mm_per_line_segment


# Arm solution configuration : Cartesian robot. Translates mm positions into stepper positions
arm_solution                                 linear_delta     # selects the delta arm solution
alpha_steps_per_mm                           80              # Steps per mm for alpha stepper
beta_steps_per_mm                            80              # Steps per mm for beta stepper
gamma_steps_per_mm                           80              # Steps per mm for gamma stepper

arm_length                                   420.68           # this is the length of an arm from hinge to hinge
arm_radius                                   211.250          # this is the horizontal distance from hinge to hinge
                                                              # when the effector is centered

# Planner module configuration : Look-ahead and acceleration configuration
planner_queue_size                           32               # DO NOT CHANGE THIS UNLESS YOU KNOW EXACTLY WHAT YOU ARE DOING
acceleration                                 3000             # Acceleration in mm/second/second.
acceleration_ticks_per_second                1000             # Number of times per second the speed is updated
junction_deviation                           0.05             # Similar to the old "max_jerk", in millimeters,
                                                              # see https://github.com/grbl/grbl/blob/master/planner.c#L409
                                                              # and https://github.com/grbl/grbl/wiki/Configuring-Grbl-v0.8
                                                              # Lower values mean being more careful, higher values means being
                                                              # faster and have more jerk
#minimum_planner_speed                       0.0              # sets the minimum planner speed in mm/sec

# Stepper module configuration
microseconds_per_step_pulse                  1                # Duration of step pulses to stepper drivers, in microseconds
base_stepping_frequency                      100000           # Base frequency for stepping

# Cartesian axis speed limits
x_axis_max_speed                             30000            # mm/min
y_axis_max_speed                             30000            # mm/min
z_axis_max_speed                             30000            # mm/min

# Stepper module pins ( ports, and pin numbers, appending "!" to the number will invert a pin )
alpha_step_pin                               2.0              # Pin for alpha stepper step signal
alpha_dir_pin                                0.5              # Pin for alpha stepper direction
alpha_en_pin                                 0.4              # Pin for alpha enable pin
alpha_current                                1.5              # X stepper motor current
alpha_max_rate                               30000.0          # mm/min

beta_step_pin                                2.1              # Pin for beta stepper step signal
beta_dir_pin                                 0.11             # Pin for beta stepper direction
beta_en_pin                                  0.10             # Pin for beta enable
beta_current                                 1.5              # Y stepper motor current
beta_max_rate                                30000.0          # mm/min

gamma_step_pin                               2.2              # Pin for gamma stepper step signal
gamma_dir_pin                                0.20             # Pin for gamma stepper direction
gamma_en_pin                                 0.19             # Pin for gamma enable
gamma_current                                1.5              # Z stepper motor current
gamma_max_rate                               30000.0          # mm/min

# Serial communications configuration ( baud rate default to 9600 if undefined )
uart0.baud_rate                              115200           # Baud rate for the default hardware serial port
second_usb_serial_enable                     false            # This enables a second usb serial port (to have both pronterface
                                                              # and a terminal connected)
#leds_disable                                true             # disable using leds after config loaded
#msd_disable                                 false            # disable the MSD (USB SDCARD) when set to true

# Extruder module configuration
extruder.hotend.enable                          true             # Whether to activate the extruder module at all. All configuration is ignored if false
extruder.hotend.steps_per_mm                    92.4             # Steps per mm for extruder stepper
extruder.hotend.default_feed_rate               600              # Default rate ( mm/minute ) for moves where only the extruder moves
extruder.hotend.acceleration                    500              # Acceleration for the stepper motor, as of 0.6, arbitrary ratio
extruder.hotend.max_speed                       70               # mm/s

extruder.hotend.step_pin                        2.3              # Pin for extruder step signal
extruder.hotend.dir_pin                         0.22             # Pin for extruder dir signal
extruder.hotend.en_pin                          0.21             # Pin for extruder enable signal

# extruder offset
#extruder.hotend.x_offset                        0                # x offset from origin in mm
#extruder.hotend.y_offset                        0                # y offset from origin in mm
#extruder.hotend.z_offset                        0                # z offset from origin in mm

# firmware retract settings when using G10/G11, these are the defaults if not defined, must be defined for each extruder if not using the defaults
#extruder.hotend.retract_length                  3               # retract length in mm
#extruder.hotend.retract_feedrate                45              # retract feedrate in mm/sec
#extruder.hotend.retract_recover_length          0               # additional length for recover
#extruder.hotend.retract_recover_feedrate        8               # recover feedrate in mm/sec (should be less than retract feedrate)
#extruder.hotend.retract_zlift_length            0               # zlift on retract in mm, 0 disables
#extruder.hotend.retract_zlift_feedrate          6000            # zlift feedrate in mm/min (Note mm/min NOT mm/sec)

delta_current                                1.5              # First extruder stepper motor current

# Second extruder module configuration example
#extruder.hotend2.enable                          true             # Whether to activate the extruder module at all. All configuration is ignored if false
#extruder.hotend2.steps_per_mm                    140              # Steps per mm for extruder stepper
#extruder.hotend2.default_feed_rate               600              # Default rate ( mm/minute ) for moves where only the extruder moves
#extruder.hotend2.acceleration                    500              # Acceleration for the stepper motor, as of 0.6, arbitrary ratio
#extruder.hotend2.max_speed                       50               # mm/s

#extruder.hotend2.step_pin                        2.8              # Pin for extruder step signal
#extruder.hotend2.dir_pin                         2.13             # Pin for extruder dir signal
#extruder.hotend2.en_pin                          4.29             # Pin for extruder enable signal

#extruder.hotend2.x_offset                        0                # x offset from origin in mm
#extruder.hotend2.y_offset                        25.0             # y offset from origin in mm
#extruder.hotend2.z_offset                        0                # z offset from origin in mm
#epsilon_current                              1.5              # Second extruder stepper motor current

# Laser module configuration
laser_module_enable                          false            # Whether to activate the laser module at all. All configuration is
                                                              # ignored if false.
#laser_module_pin                             2.5             # this pin will be PWMed to control the laser. Only P2.0 - P2.5
                                                              # can be used since laser requires hardware PWM
#laser_module_max_power                       0.8             # this is the maximum duty cycle that will be applied to the laser
#laser_module_tickle_power                    0.0             # this duty cycle will be used for travel moves to keep the laser
                                                              # active without actually burning
#laser_module_pwm_period                      20              # this sets the pwm frequency as the period in microseconds

# Hotend temperature control configuration
temperature_control.hotend.enable            true             # Whether to activate this ( "hotend" ) module at all.
                                                              # All configuration is ignored if false.
temperature_control.hotend.thermistor_pin    0.23             # Pin for the thermistor to read
temperature_control.hotend.heater_pin        2.7              # Pin that controls the heater
temperature_control.hotend.thermistor        EPCOS100K        # see http://smoothieware.org/temperaturecontrol#toc5
#temperature_control.hotend.beta             4066             # or set the beta value

temperature_control.hotend.set_m_code        104              #
temperature_control.hotend.set_and_wait_m_code 109            #
temperature_control.hotend.designator        T                #

temperature_control.hotend.p_factor         42.8             # permanently set the PID values after an auto pid
temperature_control.hotend.i_factor         2.210            #
temperature_control.hotend.d_factor         207               #

#temperature_control.hotend.max_pwm          64               # max pwm, 64 is a good value if driving a 12v resistor with 24v.

# Hotend2 temperature control configuration
#temperature_control.hotend2.enable            true             # Whether to activate this ( "hotend" ) module at all.
                                                              # All configuration is ignored if false.

#temperature_control.hotend2.thermistor_pin    0.25             # Pin for the thermistor to read
#temperature_control.hotend2.heater_pin        1.23              # Pin that controls the heater
#temperature_control.hotend2.thermistor        EPCOS100K        # http://smoothieware.org/temperaturecontrol#toc5
##temperature_control.hotend2.beta             4066             # or set the beta value

#temperature_control.hotend2.set_m_code        884              #
#temperature_control.hotend2.set_and_wait_m_code 889            #
#temperature_control.hotend2.designator        T1               #

#temperature_control.hotend2.p_factor          13.7           # permanently set the PID values after an auto pid
#temperature_control.hotend2.i_factor          0.097          #
#temperature_control.hotend2.d_factor          24             #

#temperature_control.hotend2.max_pwm          64               # max pwm, 64 is a good value if driving a 12v resistor with 24v.

temperature_control.bed.enable               true             #
temperature_control.bed.thermistor_pin       0.24             #
temperature_control.bed.heater_pin           2.4              #
temperature_control.bed.thermistor           Honeywell100K    # see http://smoothieware.org/temperaturecontrol#toc5
#temperature_control.bed.beta                4066             # or set the beta value

temperature_control.bed.set_m_code           140              #
temperature_control.bed.set_and_wait_m_code  190              #
temperature_control.bed.designator           B                #

#temperature_control.bed.bang_bang            false           # set to true to use bang bang control rather than PID
#temperature_control.bed.hysteresis           2.0             # set to the temperature in degrees C to use as hysteresis
                                                              # when using bang bang

# Switch module for fan control
switch.fan.enable                            true             #
switch.fan.input_on_command                  M106             #
switch.fan.input_off_command                 M107             #
switch.fan.output_pin                        2.6              #
switch.fan.output_type                       pwm              # pwm output settable with S parameter in the input_on_comand
#switch.fan.max_pwm                           255              # set max pwm for the pin default is 255

#switch.misc.enable                           true             #
#switch.misc.input_on_command                 M42              #
#switch.misc.input_off_command                M43              #
#switch.misc.output_pin                       2.4              #
#switch.misc.output_type                      digital          # just an on or off pin

# automatically toggle a switch at a specified temperature. Different ones of these may be defined to monitor different temperatures and switch different swithxes
# useful to turn on a fan or water pump to cool the hotend
temperatureswitch.hotend.enable              true             #
temperatureswitch.hotend.designator          T                # first character of the temperature control designator to use as the temperature sensor to monitor
temperatureswitch.hotend.switch              fan             # select which switch to use, matches the name of the defined switch
temperatureswitch.hotend.threshold_temp      60.0             # temperature to turn on (if rising) or off the switch
temperatureswitch.hotend.heatup_poll         1               # poll heatup at 15 sec intervals
temperatureswitch.hotend.cooldown_poll       60               # poll cooldown at 60 sec intervals

# Switch module for spindle control
#switch.spindle.enable                        false            #

# Endstops
endstops_enable                              true             # the endstop module is enabled by default and can be disabled here
delta_homing                                 true             # forces all three axis to home a the same time regardless of
                                                              # what is specified in G28
alpha_min_endstop                            nc               #
alpha_max_endstop                            1.25^            # add ! to invert pullup if switch is NO to ground
alpha_homing_direction                       home_to_max      # Home up
alpha_max                                    0                #
beta_min_endstop                             nc               #
beta_max_endstop                             1.27^            #
beta_homing_direction                        home_to_max      #
beta_max                                     0                #
gamma_min_endstop                            nc               #
gamma_max_endstop                            1.29^            #
gamma_homing_direction                       home_to_max      #
gamma_max                                    259.45           #

alpha_fast_homing_rate_mm_s                  200              # homing feedrates in mm/second
beta_fast_homing_rate_mm_s                   200              #
gamma_fast_homing_rate_mm_s                  200              #
alpha_slow_homing_rate_mm_s                  20               #
beta_slow_homing_rate_mm_s                   20               #
gamma_slow_homing_rate_mm_s                  20

alpha_homing_retract_mm                      15                # retract/bounce distance after homing in mm
beta_homing_retract_mm                       15                #
gamma_homing_retract_mm                      15                #

alpha_trim                                   0                 # software trim for alpha stepper endstop (in mm)
beta_trim                                    0                 # software trim for beta stepper endstop (in mm)
gamma_trim                                   0                 # software trim for gamma stepper endstop (in mm)

#endstop_debounce_count                       100              # uncomment if you get noise on your endstops

# optional Z probe
zprobe.enable                                false           # set to true to enable a zprobe
zprobe.probe_pin                             1.28!^          # pin probe is attached to if NC remove the !
zprobe.slow_feedrate                         5               # mm/sec probe feed rate
#zprobe.debounce_count                       100             # set if noisy
zprobe.fast_feedrate                         100             # move feedrate mm/sec
zprobe.probe_height                          5               # how much above bed to start probe
#gamma_min_endstop                           nc              # normally 1.28. Change to nc to prevent conflict,

# associated with zprobe the leveling strategy to use
#leveling-strategy.delta-calibration.enable   true            # basic delta calibration
#leveling-strategy.delta-calibration.radius   100             # the probe radius

# Pause button
pause_button_enable                          true             #

# Panel
panel.enable                                 false             # set to true to enable the panel code
panel.lcd                                    smoothiepanel     # set type of panel
panel.encoder_a_pin                          3.25!^            # encoder pin
panel.encoder_b_pin                          3.26!^            # encoder pin

# Example for reprap discount GLCD
# on glcd EXP1 is to left and EXP2 is to right, pin 1 is bottom left, pin 2 is top left etc.
# +5v is EXP1 pin 10, Gnd is EXP1 pin 9
#panel.lcd                                   reprap_discount_glcd     #
#panel.spi_channel                           0                 # spi channel to use  ; GLCD EXP1 Pins 3,5 (MOSI, SCLK)
#panel.spi_cs_pin                            0.16              # spi chip select     ; GLCD EXP1 Pin 4
#panel.encoder_a_pin                         3.25!^            # encoder pin         ; GLCD EXP2 Pin 3
#panel.encoder_b_pin                         3.26!^            # encoder pin         ; GLCD EXP2 Pin 5
#panel.click_button_pin                      1.30!^            # click button        ; GLCD EXP1 Pin 2
#panel.buzz_pin                              1.31              # pin for buzzer      ; GLCD EXP1 Pin 1
#panel.button_pause_pin                      2.11^             # kill/pause          ; GLCD EXP2 Pin 8 either
#panel.back_button_pin                       2.11!^            # back button         ; GLCD EXP2 Pin 8 or

# pins used with other panels
#panel.up_button_pin                         0.1!              # up button if used
#panel.down_button_pin                       0.0!              # down button if used
#panel.click_button_pin                      0.18!             # click button if used

panel.menu_offset                            0                 # some panels will need 1 here

panel.alpha_jog_feedrate                     6000              # x jogging feedrate in mm/min
panel.beta_jog_feedrate                      6000              # y jogging feedrate in mm/min
panel.gamma_jog_feedrate                     200               # z jogging feedrate in mm/min

panel.hotend_temperature                     185               # temp to set hotend when preheat is selected
panel.bed_temperature                        60                # temp to set bed when preheat is selected

# Example of a custom menu entry, which will show up in the Custom entry.
# NOTE _ gets converted to space in the menu and commands, | is used to separate multiple commands
custom_menu.power_on.enable                true              #
custom_menu.power_on.name                  Power_on          #
custom_menu.power_on.command               M80               #

custom_menu.power_off.enable               true              #
custom_menu.power_off.name                 Power_off         #
custom_menu.power_off.command              M81               #

# Only needed on a smoothieboard
currentcontrol_module_enable                 true             #

return_error_on_unhandled_gcode              false            #

# network settings
network.enable                               true            # enable the ethernet network services
network.webserver.enable                     true             # enable the webserver
network.telnet.enable                        true             # enable the telnet server
network.ip_address                           auto             # use dhcp to get ip address
# uncomment the 3 below to manually setup ip address
#network.ip_address                           192.168.3.222    # the IP address
#network.ip_mask                              255.255.255.0    # the ip mask
#network.ip_gateway                           192.168.3.1      # the gateway address
#network.mac_override                         xx.xx.xx.xx.xx.xx  # override the mac address, only do this if you have a conflict


When putting my hand on the Z axis motor, I found the motor lightly clicking when it would try to move backwards. It's weird that movement works fine when I'm manually controlling the effector though..

Here's a video: https://www.youtube.com/watch?v=3Vr68okBtZk

User avatar
KAS
ULTIMATE 3D JEDI
Posts: 1157
Joined: Thu Dec 04, 2014 6:06 pm

Re: Homes correctly, but Z axis messes up when printing

Post by KAS »

Not sure, I'm not really seeing anything different on your config from mine. Gamma direction is different, but that's for a rostock max. (gamma_dir_pin 0.20! )

When you swapped the steppers, did the issue stay on the Gamma(z) tower or did it follow that stepper? I'm thinking either a defective driver on the board, or incorrect wiring, or defective stepper.

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mlapaglia
Printmaster!
Posts: 121
Joined: Sat May 24, 2014 10:41 am
Location: Indianapolis, IN

Re: Homes correctly, but Z axis messes up when printing

Post by mlapaglia »

When switching the beta and gamma steppers and end stop the problem started happening on the beta tower.

It looks like it could be an issue with the stepper driver on the board. I've got a few spares I could swap out the SMD with a different one.

This setup came from a rostock max, i wonder why my motor doesn't need to be switched like yours.. If the stepper works correctly outside of when it's actually printing, going up and down without issue, could the stepper driver have an issue with only moving slow and not fast?

What do your repetier-host settings look like for the homing values? My x and y are set to home to 0, the z axis is home to max. None of the controls in repetier-host are set to invert the directions.

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KAS
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Joined: Thu Dec 04, 2014 6:06 pm

Re: Homes correctly, but Z axis messes up when printing

Post by KAS »

I use Simplify3D but I only use G28 to home the towers. On the stock Rostock Max v2, one of the steppers are flipped 180 from the others. So the direction on the config file has to be changed or the actual connection on the board can be flipped as-well. It looks like on yours that the stepper is mounted to the center on each tower, so that makes sense that you wouldn't need to reverse the direction on any axis.

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mlapaglia
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Joined: Sat May 24, 2014 10:41 am
Location: Indianapolis, IN

Re: Homes correctly, but Z axis messes up when printing

Post by mlapaglia »

I just swapped the smoothieboard with another one that randomly has issues with turning off, all the axis started functioning normally (except when the board freezes).

I used the same sd card on both, so they are both running the same config. I believe this defines it as a hardware problem. sigh, time for board #4...

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KAS
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Posts: 1157
Joined: Thu Dec 04, 2014 6:06 pm

Re: Homes correctly, but Z axis messes up when printing

Post by KAS »

I hear ya. Smoothieboard isn't making a good name around here in regards to the quality aspects.

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